U.S. patent application number 11/010810 was filed with the patent office on 2006-06-15 for medical devices formed with a sacrificial structure and processes of forming the same.
Invention is credited to Thomas J. Holman, Scott Schewe, Jan Weber.
Application Number | 20060129179 11/010810 |
Document ID | / |
Family ID | 36499392 |
Filed Date | 2006-06-15 |
United States Patent
Application |
20060129179 |
Kind Code |
A1 |
Weber; Jan ; et al. |
June 15, 2006 |
Medical devices formed with a sacrificial structure and processes
of forming the same
Abstract
Medical devices formed using a sacrificial structure, and
processes of forming the devices therefrom.
Inventors: |
Weber; Jan; (Maple Grove,
MN) ; Schewe; Scott; (Eden Prairie, MN) ;
Holman; Thomas J.; (Minneapolis, MN) |
Correspondence
Address: |
VIDAS, ARRETT & STEINKRAUS, P.A.
6109 BLUE CIRCLE DRIVE
SUITE 2000
MINNETONKA
MN
55343-9185
US
|
Family ID: |
36499392 |
Appl. No.: |
11/010810 |
Filed: |
December 13, 2004 |
Current U.S.
Class: |
606/194 ;
264/500; 604/264; 604/96.01 |
Current CPC
Class: |
A61M 25/0045 20130101;
A61M 25/104 20130101; A61M 2025/1075 20130101; A61M 25/0009
20130101; A61M 2025/1086 20130101; A61M 25/1029 20130101; A61M
25/1036 20130101 |
Class at
Publication: |
606/194 ;
264/500; 604/264; 604/096.01 |
International
Class: |
A61M 29/00 20060101
A61M029/00 |
Claims
1. A process of forming at least a portion of a medical device, the
process comprising the steps of: providing a sacrificial structure,
which at least in part defines the shape of said at least a portion
of said medical device; providing a durable layer over said
sacrificial structure, the durable layer forming said at least a
portion of said medical device; and eliminating said sacrificial
structure after use.
2. The process of claim 1 wherein said sacrificial structure is
provided on a mandrel.
3. The process of claim 1 wherein said sacrificial structure is
provided on a preformed substrate layer of said at least a portion
of said medical device.
4. The process of claim 1 wherein said sacrificial structure is
provided by molding.
5. The process of claim 1 further comprising the step of providing
voids in said sacrificial structure.
6. The process of claim 5 wherein said voids are provided in said
sacrificial structure by grinding, cutting or laser ablating.
7. The process of claim 5 wherein a fiber material is provided in
the voids.
8. The process of claim 5 wherein said durable layer comprises a
polymeric composition and said durable layer fills said voids.
9. The process of claim 1 wherein said sacrificial structure
defines the shape of said at least a portion of said medical
device.
10. The process of claim 9 wherein a fiber web is provided over
said sacrificial structure, the fiber web having an inner surface
and an outer surface.
11. The process of claim 10 further comprising the step of
providing a second durable layer on said inner surface of said
fibers after eliminating said sacrificial structure.
12. The process of claim 1 wherein said at least a portion of said
medical device is a balloon preform.
13. The process of claim 12 further comprising the step of molding
said balloon preform into a medical balloon.
14. The process of claim 2 wherein said mandrel comprises at least
one member selected from the group consisting of ceramic, metal,
polymeric compositions or a combination thereof.
15. The process of claim 2 wherein a first durable layer is
provided on said mandrel and said durable layer is a second durable
layer provided on said sacrificial structure.
16. The process of claim 15 further comprising the step of
providing wire in said sacrificial structure and removing said wire
after use.
17. The process of claim 15 wherein said sacrificial structure
comprises a water dispersible or water soluble polymer.
18. The process of claim 17 wherein said polymer is selected from
the group consisting of polyvinyl alcohol, polyvinyl acetate or
mixtures thereof.
19. The process of claim 18 further comprising the step of flushing
said sacrificial structure with water at a temperature of about
25.degree. C. to about 110.degree. C.
20. The process of claim 1 wherein said durable layer comprises a
thermoplastic composition, a thermosetting composition or mixtures
thereof.
21. The process of claim 20 wherein said durable layer comprises a
thermoplastic composition which comprises at least one polymer
selected from the group consisting of polyesters, polyamides,
polyolefins, polyurethanes, polyethers, polyimides, any copolymers
thereof, styrenic block copolymers and mixtures thereof.
22. The process of claim 21 wherein said at least one polymer is
selected from the group consisting of poly(ester block ester),
poly(ester block ether), poly(ether block amide), polyalkylene
terephthalate or mixture thereof.
23. A preform for a medical balloon or a catheter shaft, the
preform comprising a sacrificial material.
24. The preform of claim 23 comprising channels or voids in the
sacrificial material.
25. The preform of claim 24, said preform having a distal end
region and a proximal end region, and wherein said channels are
disposed radially spaced apart from one another in a radial
cross-sectional view, said channels extending longitudinally from
the distal end region to the proximal end region of said
preform.
26. The preform of claim 24, said preform comprising channels, and
disposed in said channels are fibers.
27. A medical device comprising: an elongate shaft having a wall
defined by an inner surface and an outer surface, the elongate
shaft having a proximal end region and a distal end region; the
inner surface of the shaft defining a central lumen; and at least
one sacrificial structure surrounded by the wall of the shaft and
extending longitudinally therethrough from the proximal end region
to the distal end region of the elongate shaft, said sacrificial
structure being removable to form at least one channel extending
longitudinally through said wall of said elongate shaft from said
proximal end region to said distal end region of said elongate
shaft.
28. The medical device of claim 27, at least two sacrificial
structures surrounded by the wall of the shaft of the elongate
shaft and extending longitudinally therethrough from the proximal
end region to the distal end region of the elongate shaft, said at
least two sacrificial structures being removable to form at least
two channels extending longitudinally through said wall of said
elongate shaft from said proximal end region to said distal end
region of said elongate shaft.
29. The medical device of claim 27, at least three sacrificial
structures surrounded by the wall of the elongate shaft and
extending longitudinally therethrough from the proximal end region
to the distal end region of the elongate shaft, said at least three
sacrificial structures being removable to form at least three
channels extending longitudinally through said wall of said
elongate shaft from said proximal end region to said distal end
region of said elongate shaft.
30. An expandable medical balloon, said balloon having a wall
defining a body, waist and cone portions, said wall comprising
fibers therein, the fibers provided in regions equidistantly spaced
in a radial cross-sectional view of said expandable medical balloon
and separated from each other by regions of the wall free of
fibers, and said fibers extending within the wall in a longitudinal
direction.
31. The expandable medical balloon of claim 30 wherein said fibers
are provided in at least three regions.
32. The expandable medical balloon of claim 30 wherein said fibers
are provided in less than 10 regions.
33. A sacrificial structure for a medical device, said sacrificial
structure forming a lumen for a catheter assembly.
34. In combination, a medical device and a sacrificial structure
over which the device has been formed.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to the field of medical
devices, and more particularly to catheters, dilatation balloons,
and the like.
[0002] Atherosclerotic cardiovascular disease is common, and is
caused by a narrowing of the arterial lining due to atherosclerotic
plaques. Balloons mounted on the distal ends of catheters are
commonly used in the medical treatment of atherosclerotic diseases.
Such balloons may be used for dilating lesions or blockages by
compressing plaque, for recanalizing and dilating a diseased
vessel, and for expanding prosthetic devices such as stents at
axdesired location in a bodily vessel. The requirements for
strength and size of the balloons vary widely depending on the
balloon's intended use and the vessel size into which the catheter
is inserted.
[0003] Percutaneous transluminal coronary angioplasty, or balloon
angioplasty, is a non-invasive, non-surgical means of treating
peripheral and coronary arteries. This technique consists of
inserting an uninflated balloon catheter into the affected artery.
Dilation of the diseased segment of artery is accomplished by
inflating the balloon which pushes the atherosclerotic lesion
outward, thereby enlarging the arterial diameter. The balloon is
then deflated and the catheter is withdrawn.
[0004] Cutting balloons are another type of medical balloon which
have cutting edges, also referred to as atherotomes or blades for
recanalizing and dilating a diseased vessel, and facilitating
balloon angioplasty procedures.
[0005] In any applications such as the above, the balloon traverses
a tortuous anatomy as it is being delivered to the location in
extremely small bodily vessels and used to open stenoses of blood
vessels by balloon inflation, or for delivery of medical devices,
for example. In these applications, it is desirable for the balloon
to assume as low a profile, i.e. the outer diameter of the balloon,
as possible. Considerable effort has been put forth in the
development of medical balloons with a low profile by minimizing
the dimensions of the shape-form or the inner tube which extends
through the balloon to its distal end, and by reducing the wall
thickness of the balloon itself.
[0006] Several methods have been employed to reduce the profile of
the dilatation catheter including manipulating the wall thickness
of the balloon material by o developing ever thinner walled
balloons, while still retaining the necessary distensibility and
burst pressure rating, so as to permit lower deflated profiles.
[0007] The profile of the deflated balloon is limited by the
thickness of the waist and cone portions of the balloon. Usually,
the waist and cone wall thicknesses are thicker than that of the
body of the balloon due to the smaller diameter of the waist and
cone portions. Thus, a reduction in thickness of the waist and cone
portions can reduce the profile.
[0008] Balloon forming techniques involve stretching and blowing of
the balloon from a segment of extruded polymer tubing. Balloons
produced by stretching and blowing a balloon preform or "parison"
can have thicker waist and cone walls than the wall thickness of
their body portions. It is desirable to reduce the thickness of the
cone walls which contribute to the overall thickness of the
catheter, to allow for improved tracking, crossing and recrossing
of lesions, and to improve refolding after use to facilitate
withdrawal of the balloon catheter.
[0009] One method of reducing the cone or waist thicknesses of a
balloon has been by laser ablating material from the cone or waist.
This is disclosed in U.S. Pat. No. 5,826,588, the entire content of
which is incorporated by reference herein.
[0010] Other methods are disclosed in commonly assigned U.S. Pat.
No. 6,193,738, the entire content of which is incorporated by
reference herein.
[0011] Thus for such applications, thin walled, high strength,
relatively inelastic balloons of predictable inflation properties
are desired. However, this combination of properties, i.e. thin
walls and low resilience, may have increased susceptibility to pin
hole formation and ruptures. Stronger balloon materials having
greater wall thickness may be employed to increase balloon
robustness, but this can also decrease balloon flexibility.
[0012] There remains a need for a balloon having improved abrasion
resistance and resistance to rupture during use, without
sacrificing flexibility, which is not subject to pin holes during
the molding process and is readily collapsible to a small diameter
upon deflation.
SUMMARY OF THE INVENTION
[0013] The present invention relates to medical devices wherein at
least a portion of the medical devices are formed using a
sacrificial structure, and to processes of forming the same.
[0014] Any type of medical device or component thereof, may be
formed according to the present invention. Examples include, but
are not limited to, catheter shafts, expandable balloons, balloon
preforms and the expandable balloons formed therefrom, catheter
tips, distal guide wire portions, etc.
[0015] While the present invention finds utility for balloons used
for coronary angioplasty procedures, the present invention also
finds utility for other types of medical balloons including, but
not limited to, cutting balloons, balloons used in the biliary
duct, urinary tract, balloons employed for the reproductive system,
expandable members for medical delivery devices including stents,
and so on and so forth.
[0016] In one aspect, the invention relates to a process of forming
a medical device or component thereof by providing a sacrificial
structure which defines at least in part the shape of the medical
device or component thereof, providing at least one durable layer
which forms at least part of the medical device over the
sacrificial structure, and eliminating the sacrificial structure
after use.
[0017] In some embodiments, the sacrificial structure defines a
member for forming a catheter shaft, medical balloon preform,
distal end of a guide wire, etc. The sacrificial structure may also
define the shape of the expandable balloon member for a catheter
assembly, and the durable layer provided over it. The sacrificial
structure is eliminated leaving the at least one durable layer
which defines the shape of the balloon.
[0018] Voids may be provided in the sacrificial structure such that
when a durable layer is deposited on the sacrificial structure, the
voids are filled by the durable layer. In such an embodiment, the
durable layer suitably comprises a polymeric composition.
[0019] After applying a first durable layer to the first
sacrificial structure, the first sacrificial structure can be
removed. The first durable layer may be applied to the inner and/or
outer surface of the sacrificial structure. A second durable layer
may be applied to the sacrificial structure as well. This second
layer may be applied over the first durable layer, or to the
opposing surface of the sacrificial structure. The second durable
layer may be the same as or different than the first durable layer.
Sacrificial layers may be applied between durable layers as well.
Furthermore, each sacrificial layer may be manipulated to provide
the durable layers which are left with voids, patterns or other
surface characteristics therein. These layers may then be
eliminated after use.
[0020] Other types of materials such as those used for
reinforcement such as fibers for example, or micro or
nano-particulate materials, can optionally be incorporated into any
durable layer, or may be incorporated in between durable layers.
These materials can also be incorporated into voids formed in the
sacrificial structure, for example, the voids then filled with the
composition which forms the durable layer. The resultant structure
has fiber reinforcement materials substantially embedded or
encapsulated therein.
[0021] The present invention may include one, two, three, four or
more sacrificial and durable layers. The additional layers may be
formed from any materials conventionally employed in the formation
of such medical devices including, but not limited to,
thermoplastic polymers, thermosetting polymers, biodegradable
polymeric materials, fibers, and so forth. Non-polymeric materials
may also be employed herein. Any combination of layers may also be
employed as will be explained in more detail in the Detailed
Description below.
[0022] The present invention allows for tailoring of physical
properties to the demands of the article being formed. For example,
the resultant medical devices can be designed for flexibility,
strength, lubricity and for having resistance to abrasions and
tearing, e.g. "rip-stop" characteristics.
[0023] The present invention also allows for tailoring of physical
characteristics of a medical device by manipulating the inner
surface of the device. For example, reducing the overall profile of
the device by manipulating the internal surface. This allows for
leaving a smooth outer surface if that is so desired.
[0024] Other aspects of the invention are described in the Detailed
Description and in the claims below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a longitudinal cross-sectional side view of a
catheter assembly having a balloon of the present invention mounted
thereon.
[0026] FIG. 1A is an enlarged view taken at section 1A in FIG.
1.
[0027] FIGS. 2A-2G are perspective views of a process of making the
tubular member similar to that shown in FIG. 2A according to the
invention.
[0028] FIG. 3 is a perspective view of a balloon according to the
invention.
[0029] FIG. 4 is a longitudinal cross-sectional view of an
alternative embodiment of a balloon preform.
[0030] FIGS. 5A-5F illustrate a process of making a balloon preform
according to the invention.
[0031] FIGS. 6A-6I illustrate a process whereby channels may be
produced in a balloon preform.
[0032] FIGS. 7A-7D illustrate an embodiment of the invention
whereby fibers are embedded in the wall of a dilatation
balloon.
[0033] FIGS. 8A-8F illustrate an embodiment of the present
invention whereby the distal sensor pocket of an intravascular
ultrasound catheter assembly is formed.
[0034] FIGS. 9A-9D illustrate an embodiment of the present
invention whereby a distal guide wire tip having a hollow core is
formed.
[0035] FIGS. 10A-10I illustrate an embodiment of the present
invention whereby a guide wire port for a rapid exchange catheter
assembly is created.
DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS
[0036] While this invention may be embodied in many different
forms, there are described in detail herein specific embodiments of
the invention. This description is an exemplification of the
principles of the invention and is not intended to limit the
invention to the particular embodiments illustrated.
[0037] All published documents, including all US patent documents,
mentioned anywhere in this application are hereby expressly
incorporated herein by reference in their entirety. Any copending
patent applications, mentioned anywhere in this application are
also hereby expressly incorporated herein by reference in their
entirety.
[0038] Some embodiments of the present invention are directed to
processes for forming medical devices, especially those deployed
and operated through various body lumens including, for example,
vascular channels, and to devices obtained from such processes.
[0039] Referring now to the figures, FIG. 1 shows balloon 10 in
combination with a catheter assembly 20. Balloon 10 may be formed
in a number of ways using a sacrificial structure (not shown)
according to the invention, several embodiments of which are
explained in detail below, and wherein the balloon includes at
least one durable layer 44 which forms at least a part of the
balloon structure. In this embodiment, durable layer 44 defines the
shape of the balloon structure. The durable layer may comprise any
suitable polymeric composition.
[0040] Catheter 20 is a representative simple over-the-wire (OTW)
or single-operator-exchange (SOE) angioplasty balloon catheter
according to the invention. Such balloon catheters are discussed,
for example, in commonly assigned U.S. Pat. Nos. 6,113,579,
6,517,515 and 6,514,228 each of which is incorporated by reference
herein in its entirety. In this embodiment, catheter 20 has an
elongate shaft assembly 26 and a conventional OTW-type manifold
assembly 28 connected to proximal end of shaft assembly 26.
Manifold assembly 28, is further shown with a strain relief 30. The
shaft assembly 26 includes an outer tube 34 coaxially disposed
about inner tube 32 which defines a guide wire lumen 36 as shown in
enlarged view in FIG. 1A, taken at section 1A in FIG. 1. This is
only an illustration of such a catheter assembly and is not
intended to limit the scope of the present invention. Numerous
structures are known to those of skill in the art, any of which may
be employed herein.
[0041] While the embodiments which follow are directed to the
formation of tubular members, it will be appreciated that
non-tubular medical articles can also be formed.
[0042] Balloon 10 shown in FIG. 1, may be formed using any
techniques known in the art, such as by directly molding the
balloon structure, or by first forming a balloon preform or
parison, and then processing the preform according to known
techniques such as by gas pressure molding, for example, into an
expandable balloon member. Balloon 10 may also be formed according
to the invention s further described below.
[0043] For the formation of a variety of articles according to the
invention, a tubular member may first be formed. Tubular members
may be used for catheter shafts, catheter tips, distal portions of
guide wires, etc.
[0044] The present invention can be used to form medical devices or
components thereof in a variety of ways. The medical devices or
components thereof may take on a variety of configurations as
described in detail below.
[0045] FIGS. 2A-2G illustrative one method of forming a member in
accordance with the invention. In this embodiment, a mandrel 18 as
shown in FIG. 2A is employed. Sacrificial structure 24 is provided
over mandrel at as shown in FIG. 2B.
[0046] In other embodiments described below, the process may start
with a sacrificial structure which defines the shape of at least a
portion of a medical device or component thereof, rather than a
mandrel.
[0047] Mandrel 18 may be formed from any suitable material known in
the art including both metals and rigid polymeric compositions. In
this embodiment, mandrel 18 is formed from a durable material.
Mandrel 18 is typically removed after use. Examples of suitable
materials include, but are not limited to, metals such as copper,
rigid polymers including fluoropolymers such as
polytetrafluoroethylene (PTFE) available under the tradename of
Teflon.RTM., acetal polymers, etc. In one embodiment, silver plated
copper is employed.
[0048] As used herein sacrificial materials include those which may
be eliminated from the resultant tubular member by melting,
dissolution, and so forth. Dissolution does not require complete
dissolution, but rather may involve partial dissolution sufficient
for removal of the shape-form from the article.
[0049] Examples of sacrificial materials include, but are not
limited to, ice, starch, sugar, waxes, solvatable polymeric
materials including those which are dispersible or soluble in water
such as polyvinyl alcohol (PVOH), polyvinyl acetate (PVA), and so
forth. Specific PVA polymers may be purchased from Adept Polymers
Limited, Unit 7, Woodrow Way, Fairhills Industrial Estate, Irlam,
Manchester, M44 6ZQ under the name of Depart Products, W-50 product
series. One such polymer has a melting temperature as measured by
DSC of 206.degree. C. Dissolution may be partial, providing that
the material is reduced to a size which is small enough such as to
be readily removable from the preform or balloon structure. Some
non-limiting examples of suitable sacrificial shape-forms are
described in commonly assigned, copending patent application Ser.
No. 10/622621, the entire content of which is incorporated by
reference herein in its entirety.
[0050] The sacrificial structure 24 may be provided over the
mandrel 18 using any method known in the art including, but not
limited to, overcoating, extruding, painting, dipping, spraying,
and so forth.
[0051] The sacrificial structure 24 can be manipulated to provide
specific features to the resultant medical device. For example,
channels, slits, indentations, or other types of voids can provided
to the surface of the medical device by ablating, grinding, cutting
or other wise removing material from the sacrificial structure 24.
Providing such characteristics in the sacrificial structure 24 can
provide surface characteristics in the durable layer after the
sacrificial structure 24 has been removed. For example, voids in
the sacrificial structure 24 result in protuberances in the durable
layer, or ultimately, in the medical device. The sacrificial
structure 24 may be removed using any means suitable for the type
of material from which it is formed, and the invention is not
limited to those listed above. Shown in FIG. 2C, a radial section
38 of sacrificial structure 24 has been completely removed. The
areas indicated by reference numeral 43, are those which have not
been further manipulated. The sacrificial structure 24 may also be
only partially removed to form a channel 40 also shown in FIG.
2C.
[0052] Alternatively as shown in FIG. 2D, sections of sacrificial
structure 24 may be completely removed in one region as shown at 38
and only partially removed in another region as shown at 42, with
no material having been removed from regions 43 of the sacrificial
structure 24.
[0053] After manipulation of sacrificial structure 24, a durable
layer 44 may be applied over sacrificial structure 24 as shown in
FIG. 2E.
[0054] As used herein, the term "durable layer" is used to describe
a layer(s) which forms at least a part of the medical device
member. Durable layer 44 may comprise any suitable thermoplastic
and/or thermosetting material for formation of medical devices.
Thermosetting materials include those cured through additive
induced, i.e. chemically induced, and/or heat or radiation induced
cross-linking. Thermosetting materials include, for example, one
and two part curing systems, moisture cures, radition cures, etc.
Thermoset materials may also include polymers, pre-polymers,
oligomers, and monomers. Curable compositions are disclosed in
commonly assigned copending U.S. patent application Ser. No.
10/622621, which has been previously incorporated by reference
herein, above.
[0055] As will be shown in embodiments discussed below, durable
layer 44 may also include fibers. Fibers are thread-like materials
which can be in the form of a monofilament, i.e. a single thread,
or in multifilament forms, i.e. a yarn, and the present invention
is not limited to any particular fiber form. For example, fibers
may be in the form of a web, mat, yarn, braid, weave, rove,
chopped, etc. The fibers may be positioned randomly, or may be
positioned uniformly. If the article being made is a balloon
preform, the fibers may be positioned such that they are on the
body, waist or cone portions of the balloon, or any combination
thereof.
[0056] Suitable fibers for use herein include both synthetic and
natural fibers. As used herein, natural fibers refer to those which
occur in nature, e.g. those produced by members of the phylum
Arthropoda including arachnids and insects such as spiders, silk
worms, black flies, wasps, and lacewing flies.
[0057] Other suitable natural fibers include, but are not limited
to, cotton, wool, help and jute.
[0058] Synthetic fibers refer to those fibers which are man-made
such as synthetic polymeric fibers, and those produced using
recombinant protein technology.
[0059] Examples of suitable synthetic high strength polymeric fiber
materials include, but not limited to, such as poly-paraphenylene
terephthalamide fibers available from DuPont de Nemours & Co.
under the tradename of Kevlar.RTM.; liquid crystal polymer fibers
such as those available from Celanese Chemicals in Dallas, Tex.
under the tradename of Vectran.RTM.; ultra high strength
polyethylene fibers such as those available from Honeywell
International in Morristown, N.J. under the tradename of
Spectra.RTM. and from Toyobo Co., Ltd. in Osaka, Japan under the
tradename of Dyneema.RTM.; polyester fibers such as those available
from Invista in Wichita, Kans. under the tradename of Dacron.RTM.;
poly-(p-phenylenebenzobisthiazole)(PBT) fibers such as Terlon.RTM.
(PBT), the "know-how" and the technical documentation for
manufacturing which is offered by license from Russian Federation,
141009, Mytischi, Moscow Region, VNIIPV; rigid-rod chain molecules
of poly(p-phenylene-2,6-benzobisoxazole)(PBO) available from Toyobo
Co., Ltd. under the tradename of Zylon.RTM., polyimide (PIM),
etc.
[0060] The above lists are intended for illustrative purposes only,
and not intended to limit the scope of the present invention.
[0061] Fibers are discussed in U.S. Pat. No. 6,746,425, and in
commonly assigned U.S. application Ser. No. 10/862250, the entire
content of which is incorporated herein by reference.
[0062] The use of fibers is not limited to any particular
embodiment, and may be employed in any of the embodiments disclosed
herein.
[0063] The fibers may be applied to a mandrel, to the sacrificial
structure or to the durable layer of the device. The durable layer
44 may fill the voids 38 created by removal of the material from
sacrificial structure 24 such that the resultant durable layer 44
left after removal of the sacrificial structure 24 has the
desirable characteristics.
[0064] Suitable thermoplastic and/or thermosetting polymeric
materials, including both elastomeric and non-elastomeric materials
may be employed in forming the composition of the durable
layer.
[0065] Thermosetting materials useful herein are disclosed in
commonly assigned copending patent application Ser. No. 10/622621,
the entire content of which is incorporated by reference herein in
its entirety.
[0066] Thermoplastic materials find particular utility herein for
use in the composition of the durable layer. Examples of
non-elastomeric materials include, but are not limited to,
polyolefins including polyethylene and polypropylene, polyesters,
polyethers, polyamides, polyurethanes, polyimides, and so forth, as
well as copolymers and terpolymers thereof. As used herein, the
term "copolymer" shall hereinafter be used to refer to any polymer
formed from two or more monomers.
[0067] Examples of suitable elastomeric materials include, but are
not limited to, elastomeric block copolymers including the styrenic
block copolymers such as styrene-ethylene/butylene-styrene (SEBS)
block copolymers disclosed in U.S. Pat. No. 5,112,900 which is
incorporated by reference herein in its entirety. Other suitable
block copolymer elastomers include, but are not limited to,
styrene-isoprene-styrene (SIS), styrene-butadiene-styrene (SBS),
styrene-isobutylene-styrene (SIBS),
styrene-ethylene/propylene-styrene (SEPS) and so forth. Block
copolymer elastomers are also described in commonly assigned U.S.
Pat. Nos. 6,406,457, 6,171,278, 6,146,356, 5,951,941, 5,830,182,
5,556,383, each of which is incorporated by reference herein in its
entirety.
[0068] Elastomeric polyesters and copolyesters may be employed
herein. Examples of elastomeric copolyesters include, but are not
limited to, poly(ester-block ether) elastomers,
poly(ester-block-ester) elastomers and so forth.
Poly(ester-block-ether) elastomers are available under the
tradename of HYTREL.RTM. from DuPont de Nemours & Co. and
consist of hard segments of polybutylene terephthalate and soft
segments based on long chain polyether glycols. Such polymers are
also available from DSM Engineering Plastics under the tradename of
ARNITEL.RTM..
[0069] Non-elastomeric polyesters and copolymers thereof may be
employed such as the polyalkylene naphthalates including
polyethylene terephthalate and polybutylene terephthalate, for
example.
[0070] Polyamides including nylon, and copolymers thereof may be
employed herein. Block copolymer elastomers such as
poly(ether-block-amides) may be employed herein and are available
from Atofina Chemicals in Philadelphia, Pa., under the tradename of
PEBAX.RTM..
[0071] The choice of material will depend on the final use to which
the medical device member will be put. Catheter shafts, for
example, may be formed from a different polymeric composition than
a catheter balloon, and the catheter balloon later disposed about
the shaft, although catheter assemblies may be formed as a
one-piece unit as well. The selection may also be based on the end
use of the balloon as well. Angioplasty balloons, for example, may
be formed from a different polymeric composition than a cutting
balloon.
[0072] For examples of suitable balloon materials see commonly
assigned U.S. Pat. Nos. 5,549,552, 5,447,497, 5,348,538, 5,550,180,
5,403,340, 6,328,925, each of which is incorporated by reference
herein in its entirety. Some specific examples of suitable balloon
materials include, but are not limited to, polyalkylene
terephthalates and polyamide copolymers such as polyethylene
terephthalate, polybutylene terephthalate, and
polyether-block-amides, for example.
[0073] The above lists are intended for illustrative purposes only,
and not as a limitation on the scope of the present invention.
Other polymeric materials not described herein, may find utility in
the formation of catheter balloons according to the invention.
[0074] The steps above can be repeated to achieve a medical device
member having a desired wall thickness. For example, as indicated
above, over sacrificial structure 24 is provided the first durable
layer. A further sacrificial layer may be deposited onto the a
first durable layer, and a second durable layer deposited onto the
sacrificial layer and so on and so forth, and not necessarily in
that order. Furthermore the first durable layer may be provided
directly on mandrel followed by sacrificial structure. Such
embodiments are discussed in more detail below.
[0075] The mandrel 18 may then be removed leaving the structure as
shown in FIG. 2F wherein the sacrificial structure 24 in this
embodiment, is still present. Sacrificial structure 24 can be
eliminated by melting or by flushing with solvent depending on the
polymeric material selected for use leaving the final structure
shown in FIG. 2G. The final structure is defined by the durable
layer 44. PVOH is readily dissolved with water at temperatures from
about 25.degree. C. to about 110.degree. C., and is only one
example of a material which may be employed in this embodiment.
[0076] A member formed by such a process as described in FIGS.
2A-2G may be suitably employed as a balloon preform shown at 12 in
FIG. 2G, which may be employed to form an expandable balloon.
[0077] Any suitable balloon forming techniques may be employed.
Such techniques are known in the art. An example of one method is
described in U.S. Pat. No. 4,490,421 to Levy which is incorporated
by reference herein in its entirety.
[0078] One method involves placing a balloon parison formed by the
process described above, in a balloon mold and expanding the
parison into the desired balloon configuration in the balloon mold.
The main processing steps may include other steps therein such as
stretching and radial orientation of the balloon material, for
example, as well as annealing and heat setting.
[0079] Shown in FIG. 3 is a conventional dilatation balloon 10
having waist 52, cone 54 and body 56 portions. One concern when
molding such balloons from a balloon preform of uniform wall
thickness, is that the cone and waist portions are expanded to a
lesser degree than the body portions, resulting in cone and waist
portions of greater wall thickness than the body. This can be a
concern with expandable medical balloons, particularly in the cone
region, for ease of deflation and rewrap of the balloon after
use.
[0080] According to one embodiment of the invention, the member 12
formed according to the process illustrated in FIGS. 2A-2G, after
removing the mandrel 18 and sacrificial structure 24 (see FIGS. 2F
and 2G), can be used as a balloon preform and can be further
processed using conventional balloon forming techniques such as by
gas pressure molding, to form dilatation balloons having cone
portions of lesser wall thickness for better deflation and rewrap
characteristics. The resultant balloon preform 12, shown in FIG. 2G
provides a central region 38 which has a greater wall thickness and
may become body portion 56 of balloon 10 shown in FIG. 3, thus
providing a molded balloon wherein the wall thickness of the body
is closer to the thickness of the cones and waist after
molding.
[0081] The above process can also be employed to form an
alternative preform structure having a stepped inner profile as
shown in FIG. 4A. In this embodiment, regions 64 and 66 of
sacrificial structure 24 may be ablated to remove material. Less
material is removed from region 64 than from region 66. No material
is ablated from region 62. A durable layer 44 is then provided over
sacrificial structure 24 as shown in FIG. 4B. A perspective view of
the resultant balloon preform 12 which has a stepped inner profile
after removal of sacrificial structure 24 is shown in FIG. 4C.
[0082] In another embodiment, a structure 24 comprising a polymeric
material such as PVA or PVOH is applied over a mandrel as
previously depicted in FIG. 2C. As discussed above, any polymeric
material may be employed provided it is readily eliminated after
the desired member has been formed. Voids 70 are provided in the
sacrificial structure 24 as shown in FIG. 5A. The voids 70 may be
produced in the sacrificial structure 24 using any suitable method.
One preferable method is laser ablation, but other methods
including grinding, cutting, and so forth, may be employed as well
as discussed above. FIG. 5B is a cross-sectional view showing the
voids in sacrificial structure 24. A durable polymeric layer 44 may
then be provided over the sacrificial structure 24 as shown in FIG.
5C. A cross-sectional depiction is shown in FIG. 5D. The mandrel 18
may removed at any time after the sacrificial structure 24 has been
applied to the mandrel. It may be desirable to remove the mandrel
18 after application of the durable layer 44, however, this is not
necessary. The sacrificial structure 24 may be removed after
removal of the mandrel 18 and after application of the durable
layer 44 using appropriate means. If sacrificial structure 24 is
formed with a water dispersible or soluble polymer such as PVA or
PVOH, employing a water flush at a temperature between about
25.degree. C. and about 110.degree. C., readily eliminates
sacrificial structure 24.
[0083] FIG. 5E is a longitudinal cross-sectional view of a balloon
preform 12', which has been formed by the method described in FIGS.
5A-5D. The balloon preform exhibits projections 72 on the inner
surface 73 of the durable layer 44 which defines the balloon
preform 12'. Projections 72 project inward toward lumen 75 of
balloon preform 12'. FIG. 5F is a radial cross-sectional view of
the preform 12' of FIG. 5E.
[0084] FIGS. 6A-6G illustrate another method whereby a member for a
medical device is formed according to the invention. The method is
illustrated by use of radial cross-sectional depictions of each
step conducted in the formation of the article. FIG. 6A is a radial
cross-section of mandrel 18. A first durable layer 44a is provided
over mandrel 18 as shown in FIG. 6B such as by extrusion or other
suitable method. A sacrificial structure 24 is provided over first
durable layer 44a as shown in FIG. 6C. The sacrificial structure 24
may be extruded over durable layer 44a and has members or wires 74
extending therethrough. The wires 74 may be in the form of metal or
polymeric wire such as those formed from nylon, polyester, and so
forth, and any number from one wire or more may be employed. First
sacrificial structure 24 may be provided over first durable layer
44a simultaneously through the use of coextrusion techniques, or as
a sequential step. Voids or notches 70 are provided in the first
sacrificial structure 24 using any suitable method such as by laser
ablation or other technique, and may be provided either radially or
longitudinally in the structure 24 as shown as shown in FIG.
6D.
[0085] A second durable layer 44b is then provided over the first
sacrificial structure 24 now filling the voids as shown in FIG. 6E.
Both the mandrel 18 and the wires 74 may then be removed leaving a
central lumen 78 and smaller lumens 76 which run in a longitudinal
direction with the tube as shown in FIG. 6F. Solvent, indicated by
arrow 77, may be flushed through lumens 76 to eliminate the
sacrificial structure 24 and form channels 80 as shown in FIG. 6G.
If a water dispersible or water soluble polymer is employed, water
may be used to flush and eliminate sacrificial structure 24 from
the structure. The resultant structure 81 shown in radial
cross-section in FIG. 6G may also be further processed to form an
expandable balloon member.
[0086] If the structure resulting from the process of FIGS. 6A-6G
is a catheter shaft, the channels may be formed such that when the
catheter assembly is in use, the channels are in fluid
communication with a body lumen at the distal end region of the
shaft.
[0087] Composite structures may also be prepared by the inventive
processes. For example, materials employed for reinforcement of a
medical device or component thereof may be employed herein. For
example, both natural and synthetic fibers may be employed for
wrapping, braiding, winding, roving, knitting, weaving, and so
forth. Pre-formed fiber structures such as those in the form of a
mesh, net, or chopped fiber mats may also be employed and slid into
place over the desired structure. Furthermore, fibers which have
been chopped into small pieces may be randomly applied.
Monofilament as well as multi-filament fiber may be employed
herein.
[0088] Both synthetic, i.e. man-made, and natural fibers may be
employed herein. Natural fibers refer to those which occur in
nature such as silk fibers produced by members of the phylum
Arthropoda including arachnids and insects such as spiders, silk
worms, black flies, wasps, and lacewing flies, while synthetic
fibers refer to those fibers which are man-made such as those
produced using recombinant protein technology. For example,
synthetic spider silk may be produced using recombinant protein
technology. Recombinant spider silk protein has been found to
produce fiber having a suitable balance of properties including
flexibility, strength and biocompatibility. Fibers of this nature
are disclosed in commonly assigned copending U.S. patent
application Ser. No. 10/862250 filed Jun. 7, 2004, which is
incorporated by reference herein in its entirety.
[0089] Examples of synthetic fibers include, but are not limited
to, SPECTRA.RTM., liquid crystal polymer fibers such as Ticona
VECTRAN.RTM. liquid crystal polymer fibers, DuPont KEVLAR.RTM.
aramid fiber, or other, polyimide, polyester, ultra high molecular
weight polyethylene fibers, glass, flexible ceramic, carbon,
metallic material, and so on and so forth. Nano fibers may also be
employed herein.
[0090] The durable layer may be provided over the fibers by
spraying, extruding, dipping, painting, and so forth. After removal
of the mandrel and the sacrificial structure, another durable layer
may be provided on the inner surface of the structure such as the
member described in FIGS. 6A-6G. These members may be used as
balloon preforms and further processed into balloon structures.
[0091] FIG. 7A-7D illustrate an embodiment whereby fiber
reinforcement is inserted into an ablated area of the sacrificial
structure, overcoated, and the sacrificial structure is eliminated.
The inner surface of the resultant structure may be coated after
elimination of the sacrificial structure such that the fiber
reinforcement is encapsulated in the durable layer.
[0092] FIG. 7A illustrates a sacrificial structure 24 overcoated on
mandrel 18. Voids 70 running in a longitudinal direction have been
produced in sacrificial structure 24 can be produced using any
method known in the art. Located in the voids 70 of sacrificial
structure 24 are fibers 90. A composition for increasing friction
or an adhesive composition may be employed between the fibers 90
and the sacrificial structure 24. The adhesive composition may be
any suitable adhesive composition known in the art including
thermoplastic and thermosetting compositions including radiation
curable compositions such as those cured using UV radiation.
Examples of suitable polymeric materials employed in the adhesive
compositions include, but are not limited to polyurethanes,
polyamides, polyolefins, polyesters, polyimides, polyethers, block
copolymer elastomers including those having styrene end-blocks and
midblocks of propylene, ethylene, butylenes, butadiene, isoprene,
etc., as well as any copolymers thereof. Gum rosins also find
utility by themselves, or in combination with other adhesive
components.
[0093] The sacrificial structure may then be coated with a durable
layer 44. Mandrel 18 may then be removed and sacrificial structure
24 eliminated as described above. To fully encapsulate the fibers,
another layer of durable material may be coated on the inside (not
shown). The resultant member has projections 72 on the inner
surface 73 of the member 12'' defined by durable layer 44.
Projections 72 project inward toward the lumen 75 of the member
12''. The process results in a member 12'' which may be employed as
a balloon preform as shown in FIG. 7B. Fibers 90 are now embedded
in the preform wall as shown by the cross-sectional depiction shown
in FIG. 7C.
[0094] As shown in a radial cross-sectional view FIG. 7C, the
fibers 90 are spaced equidistantly in a radial direction. In
between the regions of the durable layer 44 having fibers 90, are
regions which have no fibers. While, the member 12'' of FIG. 7C, is
shown having three regions comprising fibers, any number of
fiber-containing regions may be incorporated into the structure as
desired.
[0095] Member 12'', employed as a balloon preform, may then be
further processed as described above, using any balloon molding
techniques known in the art as discussed above into expandable
medical balloon 10'' shown in FIG. 7D. In this embodiment, balloon
body 56 is reinforced with fibers 90 which are located within
projections 72 on the inner surface 73 of the balloon member,
leaving the cone portions 54 and waist portions 52 unreinforced.
The fibers 90 are shown extending longitudinally in balloon body
60.
[0096] Other types of materials may also be employed to build a
composite structure such as radioapaque materials, conductive
materials, ceramic, carbon, and so on and so forth. These types of
materials can be readily embedded in the walls of the medical
device employing the method of the present application.
[0097] Another embodiment of the present invention illustrates
formation of a distal sensor pocket for an intravascular ultrasound
catheter assembly. A sacrificial structure 92 is formed according
to the present specification as shown in partial longitudinal
cross-section in FIG. 8A and in radial cross-section in FIG. 8B.
Sacrificial structure 92 may be formed using any conventional
molding techniques. A durable layer 96 may be applied to the
sacrificial structure 92 using any conventional methods such as
overcoating, molding, extruding, etc. as shown in FIG. 8C. FIG. 8D
is a radial cross-sectional view taken at section 8D-8D in FIG.
8C.
[0098] The sacrificial structure may then be eliminated using
appropriate methods as determined by the type of material from
which the sacrificial structure is formed. For example, water or
solvent if the sacrificial structure is water dispersible or
soluble. Once the sacrificial structure is eliminated, a sensor
pocket 98 is formed at the distal end 94 of intravascular
ultrasound catheter assembly 100 shown in partial longitudinal
cross-section in FIG. 8E. FIG. 8F is a radial cross-sectional view
taken at section 8F-8F in FIG. 8E.
[0099] In another embodiment, a hollow polymeric guide wire tip is
formed according to the invention. Sacrificial structure 102 is
formed by molding or extruding, for example, and is shown in
partial longitudinal cross-section in FIG. 9A. A durable layer 104
is deposited onto sacrificial structure by overcoating, extruding,
coextruding, molding, etc. If extrusion techniques or overcoating
techniques are employed, the durable layer may appear as shown in
partial longitudinal cross-section in FIG. 9B. The durable layer
104 then may be manipulated using any known techniques such as by
mechanical grinding or laser ablation techniques, to form a guide
wire tip 106 having a configuration as shown in FIGS. 9C or 9D.
However, molding techniques may yield a guide wire tip 106 without
any further manipulation, by employing a mold in the desired shape.
The sacrificial structure 102, may then be eliminated, leaving a
guide wire tip 106, having a hollow core 108. Guide wire tip 106
may then be secured to a hollow guide wire. The resultant assembly
may be employed for delivery of therapeutic substances, for
example.
[0100] The present invention may also be employed in the
manufacture of ports for catheter assemblies. In one embodiment,
the present invention is employed for making a guide wire port for
a rapid exchange (RX) or single operator exchange (SOE) catheter
delivery device.
[0101] FIG. 10A is a perspective view of a sacrificial structure
124 having a lumen 110, and a moon-shaped depression 112 in the
outer surface. Sacrificial structure 124 may be formed by injection
molding and may be formed with materials described above such as
PVA or PVOH which can be easily flushed from an assembly once the
sacrificial structure 124 has served its purpose. FIGS. 10B, 10C
and 10D are radial cross-sectional depictions taken at sections
B-B, C-C and D-D of FIG. 10A respectively.
[0102] Sacrificial structure 124 may be inserted into an outer
catheter shaft 114, having a side opening 116 formed in the wall
119 of catheter shaft 114 as shown perspectivley in FIG. 10E. Outer
catheter shaft 114 may be formed using methods known in the art
such as by extrusion, for example. This type of outer catheter
shaft construction may be employed in a single operator exchange
(SOE) catheter, which may also be referred to in the industry as a
rapid exchange (RX) catheter.
[0103] An inner catheter shaft 120 may then be inserted into the
depression 112 of sacrificial structure 124 and through opening 116
in outer shaft 114 as depicted in FIGS. 10F and 10G. FIG. 10G is a
fragmentary view of the distal end of the SOE catheter with
catheter balloon 122. Inner shaft 120 may be secured to outer shaft
114 at opening 116 by methods known in the art including welding,
adhesively, etc. Welding may be conducted using a laser, for
example.
[0104] Balloon 122 may be secured to the distal end of the inner
shaft 120 using methods known in the art by welding, adhesively,
etc. as shown in FIG. 10G.
[0105] Once the balloon has been assembled over the outer shaft,
the sacrificial structure may be removed by appropriate methods
such as by flushing in the case of a sacrificial structure formed
with PVA or PVOH.
[0106] FIG. 10H is a view similar to that of FIG. 10G with part
removed by process, illustrating the balloon catheter assembly
after the sacrificial structure has been removed from the assembly
showing catheter balloon 122 over the inner shaft 120 at the distal
end and over the outer shaft 114 at the proximal end of balloon
122. Removal of the sacrificial structure leaves a lumen between
the inner shaft 120 and the outer shaft 114. At this time, inner
shaft 120 may be secured at the distal end 126 of balloon 122 by
methods known in the art including welding, adhesively, etc. FIG.
10I is a perspective view similar to that of FIG. 10H showing
distal end of invention completely assembled with balloon 122
secured at the distal end to the inner shaft 120.
[0107] SOE catheters are discussed in U.S. Pat. No. 5,833,706
incorporated by reference herein in its entirety.
[0108] The above examples are intended for illustrative purposes
only, and not as a limitation on the scope of the present
invention.
[0109] The above disclosure is intended to be illustrative and not
exhaustive. This description will suggest many variations and
alternatives to one of ordinary skill in this art. All these
alternatives and variations are intended to be included within the
scope of the attached claims. Those familiar with the art may
recognize other equivalents to the specific embodiments described
herein which equivalents are also intended to be encompassed by the
claims attached hereto.
* * * * *